Modification of crystalline structure of crystallizable high polymers



United States Patent 3,367,926 MQDIFICATION OF CRYSTALLINE STRUCTURE OF CRYSTALLIZABLE HIGH POLYMERS John'F. Voeks, Pleasant Hill, Calif., assignor to The Dow Chemical Company, Midland, Mich., a corporation of Delaware No Drawing. Filed Mar. 25, 1964, Ser. No. 354,790 12 Claims. (Cl. 26093.5)

This invention relates to thermoplastic high polymers, particularly hydrocarbon polymers such as u-olefin polymers, which on cooling from a molten condition are capable of crystallizing with formation of crystallites and spherulites. More particularly, it pertains to modifying the crystalline structure of such polymers by effecting the crystallization thereof by cooling from a molten condition in the presence of added nucleation agents.

It is characteristic of many crystallizable high polymers such as isotactic polypropylene that a melt of the polymer can be cooled to a temperature considerably below the melting point of its crystallized form before the molten polymer beings to crystallize. The extent of such supercooling which can be obtained depends on many factors, including the rate of cooling. The structure of the resulting crystallized product and many of its properties are dependent, inter alia, on the extent of supercooling of the melt before crystallization.

Generally, a crystallized polymer obtained by rapid cooling of a melted polymer to a relatively low crystallization temperature has a short-range crystalline order (variously called smetic, paracrystalline, or hexagonal crystalline) and contains many small, uniform spherulites; the resulting products have higher impact strength and tensile strength, lower tensile modulus and stiffness, and better clarity and transparency than products of slow cooling. Conversely, a crystallized polymer obtained by slow cooling of a melted polymer in a temperature range just below the crystalline melting point has a crystalline order (usually monoclinic) characterized by relatively high degree of crystallinity and relatively large spherulites; the resulting products have lower impact strength and tensile strength, higher tensile modulus and stiffness, and greater tendency to scatter light, making the products appear opaque.

It is apparent that the most desirable combination of properties, i.e. optimum toughness, clarity, and rigidity, is not obtainable in such products by either rapid cooling or slow cooling. In fact, molded articles made by melting, shaping, and cooling such polymer materials in usual fabrication processes have properties which are not optimum in any regard.

A better combination of physical properties in molded products of thermoplastic crystallizable high polymers can be obtained by rapidly chilling the melted plastic to produce very small spherulites and subsequently annealing the product at an elevated temperature (below the crystalline melting point) to increase the degree and perfection of crystallinity. However, such complex procedures are expensive and are limited to shapes having simple, uniform cross-sections such as foils or filaments. Where the two-step chill-anneal process is impractical or where high speed molding cycles are desired (as in injection molding) it would be desirable to carry out the crystallization rapidly and to a high degree, at a relatively high temperature, with formation of relatively small spherulites.

It is now known from U.S. Patent 2,991,264 to partially crystallize an a-olefin polymer such as polyethylene by incorporating small amounts of filler materials which are solid and insoluble in the molten polymer and which are very small in size of particles, preferably colloidal or 3,367,926 Patented Feb. 6, 1968 super-colloidal (super-colloidal particles of silica are preferred), whereby the rate of crystallization of the polymer is enhanced.

It is an object of this invention to provide improvements in fabrication of thermoplastic crystallizable high polymers. A more particular object is to provide improvements in means for modifying the crystalline structure of such polymers when a quantity thereof is cooled from a molten condition to a solid condition. Another object is to provide means for effecting rapid crystallization of such polymers at a relatively high temperature, with formation of relatively small spherulites. A further object is to provide means for improving the physical and mechanical properties of plastic products of such polymers by modification of the crystalline structure of such polymers. A still more particular object is to provide such means for the fabrication of articles, from thermoplastic crystallizable high polymers, having in combination optimum properties of degree of crystallinity, stiffness, clarity, and toughness. Another object is to provide such means of fabrication of plastic articles at high speed, e.g. by molding with short molding cycle.

Other objects and advantages of the invention will be evident from the following description of the invention.

The objects of this invention are attained by modifying the crystalline structure of thermoplastic crystallizable high polymers by effecting the crystallization thereof by cooling the polymer from a molten condition to a solid condition in the presence of certain added nucleation agents as fully set forth hereinafter.

We have found that, in the conversion of a molten mass of crystallizable high polymer to a crystallized solid mass, it is the nucleation step which is the slow step and which is the most amenable to modification and control to effect improvements in the fabrication process and in the resulting product. We have further found that suitable added nucleation agents in the cooling molten polymer mass bring about formation of large numbers of sites of crystallization at relatively high temperatures (relatively less supercooling below the crystallinic melting point), whereby crystallization takes place rapidly, to a high degree and with formation of small crystallites 'and spherulites.

The nucleation agents for use in this invention are compounds having a sterically ordered polar structure which provides strong interaction with the polymer chain there by inducing steric order into the mobile plastic system as the polymer melt is cooled. It is probable that the nucleators are wetted by the molten polymer.

The effect induced by the added nucleation agents is a physical, steric effect, and the nucleators are characterized as a class on the basis of physical properties as distinguished from chemical properties in the classical sense. For convenience, as shown hereinafter, examples of nucleation agents can be grouped in accordance with their chemical structure but the diversity of such structures is evidence that their function is primarily physical.

Specific illustrations of suitable nucleating agents are given below in connection with the examples.

Any thermoplastic crystallizable high polymer can be used in accordance with this invention, but its benefits are particularly advantageous in those polymers which, on rapid cooling from a melted condition, normally exhibit pronounced tendency to supercool in non-crystalline state until the temperature is substantially below their crystalline melting points and which, on slow cooling from a melted condition, tend to form large spehrulites. Among such polymers are olefin hydrocarbon crystallizable polymers, particularly stereo-regular polymers such as isotactic polypropylene, isotactic poly(-3-methy1butene-l), isotactic poly(4-methylpentene-1), isotactic polystyrene,

and other isotactic and syndiotactic poly(a-olefins) and derivatives thereof, crystallizable vinylidene chloride polymers (saran polymers), polyoxymethylene polymers, and crystallizable copolymers of ethylene and vinyl acetate, ethylene and ethyl acryla'te, and the like.

The active nucleating agents can be incorporated in the crystallizable high polymer in effective proportionate amount from about parts per million by weight based on the polymer. While there is no upper limit from the standpoint of providing or negating nucleation effect, amounts of added agent above about to about 50 percent are usually used for additional, secondary benefits, for example as a filler or in preparation of master batches and the like. In ultimate compositions consisting essentially of the crystallizable polymer and the nucleator, from about 0.005 to about 1.0 percent by weight of added nucleation agent based on the crystallizable polymer is preferred, depending on other factors as indicated below. In compositions also containing added stabilizers, pigments, fillers, mold release agents, and the like, a larger proportionate amount of nucleating agent may be required to produce the desired effect.

The particle size of the added nucleating agent is not critical from the standpoint of the qualitative effect on nucleation. In general, small particle size is preferred for ease of obtaining intimate mixing and thorough distribution through the polymer. Usually, the smaller the particle size, the less nucleator is needed to provide a desired effect on crystallization, and better clarity of transparent plastic compositions is obtained with smaller particles. However, it is the ultimate particle size which is controlling, rather than the starting size of the material used, since some nucleation materials undergo further subdivision during fabrication of the plastic composition. In instances where optical properties of the product are not important, e.g. in opaque pigmented or filled articles, or where the index of refraction of the nucleator is nearly the same as that of the polymer, or where the starting particles of nucleation agent break down to small ultimate particles during fabrication, the nucleating agent particles can be relatively larger. In practice, nucleators passing an 80 mesh screen (U. S. Standard Sieve Series) (less than about 175 microns) are suitable for most applications. Particles in the order of 5 microns or smaller up to about 800 microns can be used.

The added nucleation agents are incorporated into the polymer by mixing means. Finely divided nucleator and finely divided solid polymer can be mechanically admixed, but better results are usually obtained by fluidizing the polymer, e.g. dissolving the polymer in a liquid solvent, adding the finely divided nucleator to the polymer solution, and evaporating the solvent from an intimate mixture of polymer and nucleator. The preferred procedure is to thoroughly admix the finely divided nucleating agent with the polymer in heat plastified or melted condition.

The advantages of the present invention are obtained when a composition comprising in intimate admixture a thermoplastic, crystallizable high polymer and a nucleation effective proportionate amount of a nucleation agent as described, at a temperature above the crystalline melting point of the polymer but below the decomposition temperature of the ingredients of the mixture, is cooled to a temperature below the crystalline melting point of the polymer. The absolute temperatures are not critical provided the relative temperatures are respected in consideration of the particular crystallizable polymer and nucleating agent employed, and, in turn, the nucleating agent must be selected in consideration of the temperatures necessary to put the particular crystallizable polymer in molten condition; that is, the particular nucleation agent used must be thermally stable above the crystallizable polymer melting point, and the nucleator must exist at least in part in a sterically regular configuration when the temperature of the composition is cooled below the crystalline melting point of the polymer.

It is within the ordinary skill of the art to select the optimum rate of cooling of the nucleated polymer composition from a temperature above the crystalline melting point of the polymer to tempera-tures below such point in consideration of the particular kind of polymer and kind and proportion of nucleating agent present in the composition and the crystalline structure desired in the product. In general, nucleated compositions in accordance with this invention crystallize at a higher temperature (less supercooling) and at higher rates (from more centers of nucleation) than do otherwise similar compositions absent the added nucleation agent. However, with slow crystallizing polymers, an ultra-fast cooling rate may mask or diminish the benefits of this invention in some instances.

For the fabrication of useful articles, the nucleated composition is made up at a temperature above the crystalline melting point of the polymer but below the decomposition point of the ingredients of the composition, as before described, or is reheated to such temperature, and, while in heat-plastified condition, is fabricated into useful or potentially useful shapes such as fibers, filaments, films, sheets, rods, tubes, or other extruded articles, or is molded by compression or injection or otherwise into molded articles and subsequently cooled to set up the shape and induce crystalliaztion. In a particular embodiment, a heat-plastified nucleated plastic composition as herein described is melt extruded through a long narrow slit die into a film which is carried over cooling rolls or through cooling baths of liquid or gas for controlled temperature conditioning until crystallization has occurred, then cooled to room temperature and taken to storage. In another particular embodiment, a heat-plastified nucleated plastic composition of the kind herein described is pressed by compression or injection into a mold space and cooled at a predetermined rate in the mold until the mass is set up and crystallized, after which the mold is opened and the molded article is ejected.

The following examples illustrate the invention but are not to be construed as limiting its scope.

In connection with the examples, numerous nucleationactive agents are employed, these agents being identified in Tables 19 as follows.

TABLE l.-NUCLEATING AGENTS Salts of carboxylic acids containing an aromatic group Code Name ll-Lithium benzoate 12Sodium benzoate 13Potassium benzoate 14Rubidium benzoate 15Calcium benzoate 16Strontium benzoate l-7Barium benzoate l-8-Nickel benzoate l9-Silver benzoate l-10Zinc benzoate l11-Aluminum benzoate 1-12Bismuth benzoate l13-Sodium salicylate ll4Strontium salicylate ll5Sodium p-aminobenzoate l16Potassium p-aminobenzoate ll7--Sodium o-chlorobenzoate ll8-Sodium p-chlorobenzoate 119Sodium p-tolulate l-20Sodium ptert-butylbenzoate l2l-Potassium p-tert-butylbenzoate l22Nickel-p-tert-butylbenzoate 1-23Sodium phenylpyruvate 124Sodium mandelate l-25-Sodium nicotinate l--26Diso lium phllialate l-27 -Disodium tcrcphthalale l28--Potassium biphthalate 7 TABLE 3.NUCLEATING AGENTSCnt. Code: Name 3-l5p,p'-Oxydibenzoic acid 3-16-2,4-dichlorophenoxyacetic acid 3-17--Mesitylacetic acid 3-18Isonicotinic acid 3-19--Tetraphenyl-1,2-dihydrophthalic anhydride 320-9-fiuorencarboxylic acid 3-2lTerephtha1ic acid 322-Isophthalic acid 3-23-Phthalic anhydride TABLE 4.-NUCLEATING AGENTS Carboxylic acids and anhydrid s cont ining no aromatic grouping Code: Name 41Adipic acid 42-L-ascorbic acid 43D,L-camphoric acid 44--3,6-endomethylene 1,2,3,6 tetrahydrophthalic acid TABLE 5.NUCLEATING AGENTS Amino acids, their salts and proteins Code: Name 51Glycine 5-2Sodium glycinate 5-3Potassium N-phenylglycinate 5-4P0tassium phenylglycinate 55--D,L-alanine 562-methylalanine 57-D,L-a-aminoisobutyric acid 5'8D,L-va1ine 59D,L-leucine 5l0L-isoleucine 5-1lD,L-2-methylleucine 512--Tyrosine 513Crystallized bovine plasma TABLE 6.NUCLEATING AGENTS Compounds containing sulfur Code: Name 6-1Sodium benzenesulfonate 6-2-Potassium benzenesulfonate 63--Sodium p-toluenesulfonate 64Sodium 3-4-dichlorobenzene-l-sulfonate 65Sodium diphenyl-4-sulfonate 66Sodium m-diphenylbenzenesulfonate 67-S0dium tetrahydronaphthalenesulfonate 68Potassium a-naphthylsulfonate 6-9Sodium a-naphthylsulfonate 6-l0 Sodium Z-anthraquinonesulfonate 611Sodium p-diphenylaminesulfonate 6l2--Barium diphenylaminesulfonate 6-13Sodium alizarinsulfonate 6l4-Aluminum p-toluenesulfonate 615%odium toluenesulfinate 6-1 6Sulfani1amide 617-o-Sulfobenzoic acid imide (saccharin) 618fiSodium cyclohexylsulfamate (sodium sucaryl) 619-Potassium cyclohexylsulfamate 620-Ammonium cyclohexylsulfamate 621--Calcium cyclohexylsulfarnate 622-Magnesium cyclohexylsulfamate 623-Thiourea -624Monopotassium p-sulfobenzoate 625-Sodium p-bromobenzenesulfonate 626-Sodium p-chlorobenzenesulfonate 627-S0dium thiobenzoate 628-Sodium 2-naphthalenesulfonate 629-Sodium thiophene-Z-carboxylate 6-30Sodium 2,4-dimethylbenzenesulfonate 63 l-Sodium 2,5-dimethylbenzenesulfonate 6-32Disodium m-benzenedisulfonate 6-33Disodium o-mercaptobenzoate 634-Mono-sodium rn-sulfobenzoate 8 TABLE 7.NUCLEATING AGENTS Non-acidic Organic compounds containing an aromatic group Code: Name 7-1-o-Terphenyl 72m-Terphenyl 73-p-Terphenyl 74-2,3,5,6-tetramethylbenzamide 752,4,S-trimethylbenzamide 7-6Sodium p-cyclohexylphenoxide 7-7-Fluorescein 78Zinc chelate of disalicylalethylenediimine 79-Copper chelate of disalicylalethylenediimine 710-Zinc complex of N,N-dimethyldithiooxamide 71 1p-Bis diphenylhydroxysilyl benzene 712-Sodium phenylphosphinate 713Hydroquinone 7-l4-Anthraquinone 715-Poly(ethylene terephthalate) 7-16-Nylon resin 401 717Phthalocyanine, metal free 718-Copper phthalocyanine 719Phthalhydrazide 720-Sodium phenolate 721Ferrocene TABLE 8.-NUCLEATING AGENTS Non-acidic organic compounds not containing an aromatic group Code: Name 81P0lyoxymethylene 82Dipentaerythritol 83-Pentaerythritol 84Inositol TABLE 9.NUCLEATING AGENTS Inorganic compounds Code: Name 91-Calcium oxide 9-'2-Magnesium oxide 93Titanium dioxide 94-Aluminum sodium sulfate 9-5-Aluminum ammonium sulfate 96Alurninum potassium sulfate The nucleating agents listed in Table 1 are salts of carboxylic acids containing an aromatic group. Both metallic and non-metallic salts are represented. Metals and metalloids from Periodic Groups I, II, III, IV, V, VII and VIII are shown. Monoand poly-carboxylic acids are represented by carbocyclic groups (the benzene nu cleus and the naphthalene nucleus) and by N-heterocyclic groups having aromatic character (the pyridine ring). Also included are salts of acids having other substituents such as halogen, hydroxyl, alkoxy, aroxy, and amino. The agents listed in Table 3 are carboxylic acids and anhydrides containing an aromatic group, also showing wide variety in kind of aromatic group, number and portion of the carboxyl group, and kind of other su-bstituent. Together, the agents illustrated in Tables 1 and 3 are carboxylic acids containing an aromatic group and anhydrides and salts thereof.

The nucleating agents listed in Table 2 are salts of diverse carboxylic acids containing no aromatic group. Solid carboxylic acids containing no aromatic group are illustrated in Table 4.

The nucleating agents listed in Table 5 are amino acids and derivatives thereof as salts and proteins.

Together, the agents shown in Tables 1 through 5 are normally solid carboxylic acids and anhydrides and normally solid derivatives of carboxylic acids, such as salts, of many diverse kinds.

The nucleating agents listed in Table 6 are diverse com-pounds containing sulfur including sulfonates, sulfinate, sulfonamide, sulfo-imide, and sulfamate groups. Those listed in Tables 7 and 8 are diverse other non-acidic organic compounds. Inorganic nucleating agents are illustrated in Table 9.

For purpose of demonstrating the effect of added nucleation agents on the crystallization of crystallizable polymers in accordance with this invention, several test procedures were used as indicated in the examples that follow.

In some instances the crystallization behavior of the compositions was measured by differential thermal analysis (DTA), the principles of which were described by Bacon Ke in the Journal of Polymer Science, XLII, -23 (1960). In accordance with this analysis, a sample of the polymer composition is premelted under vacuum in the aluminum test block, e.g., at 200 C. in the case of polypropylene compositions, allowed to relax, e.g. for ten minutes, then subjected to a constant linear rate of cooling. The temperature diiferential between the test material and the reference material (in this case a chemically inert silicone fluid) is automatically plotted graphically as a function of the temperature of the reference material. As crystallization of the crystallizable polymer takes place, the plotted differential rises to a peak or maximum and then diminishes. In each test, the temperature at which the differential begins to rise is taken as the initial temperature of crystallization and the temperature at which the peak occurs is taken as the peak temperature of the crystallization. Polymer compositions containing relatively more effective nucleation agents result in relatively higher initial and peak temperatures of crystallization in the DTA test method.

In some instances the crystallization behavior of the compositions was observed and measured by depolarized light intensity technique (DLIT) in which the polymer composition comprising an added nucleation agent is melted between a microscope slide and cover glass and transferred to the hot stage of a microscope. Two different subsequent techniques are then employed. In one, a constant rate of cooling is used and the temperatures at which the intensity of the depolarized light passing through the sample begins to change and ceases changing are noted; the higher the values of such temperatures for a given base polymer the more effective is the nucleation agent in initiating crystallization. In the other technique, an isothermal procedure is used wherein the composition on the hot stage is held at a constant temperature below the crystalline melting point of the polymer and the time before first change in the intensity of the transmitted depolarized light through the sample is taken as the induction time; the shorter the induction time in the DLIT test, the more effective is the nucleation agent in initiating crystallization.

The effect of added nucleation agents on the physical and mechanical properties of the resulting plastic products is also shown by measuring such properties, especially tensile properties of yield strength and tensile modulus, in standard test methods.

Example 1 Various compositions of isotactic polypropylene as exemplary of a thermoplastic, crystallizable high polymer, and of nucleation agents identified in Tables 1 through 9, as exemplary of nucleation agents suitable for use in accordance with this invention, were prepared. Table 10 identifies the added nucleating agent by reference to Tables 1 through 9 and indicates the concentration thereof in the polymer composition. The compositions were generally prepared by stirring the additive into the molten polymer. The resulting compositions were tested by the Differential Thermal Analysis (DTA) method hereinbefore described. The initial and peak temperatures, in degrees centigrade, for the compositions are shown in Table 10. The polypropylene used was prevailingly isotactic polypropylene having melt index of 7.5 dg./min.

and contained about 6 percent by weight of polymer soluble in cold xylene.

TABLE 10 [Evaluation of nucleation agents in polypropylene using differential thermal analysis] Nucleating Agent DTA, 0. Test Mixing No. Code Coneentra- Method Initial Peak Tables 1-9 tion, Percent Blank, no additive 123 102 Blank, no additive 121 103 Blank, no additive 121 103 Blank, no additive 121 105 1-19 0. 3 1 139 127 7-13 0. 5 2 139 113 1-20 0. 5 1 138 126 1-2 0. 1 1 138 128 6-10 0. 5 2 138 117 6-10 0. 1 1 138 124 1-9 0. 5 2 136 117 6-5 0. 1 1 136 122 3-14 0. 5 2 136 115 6-12 0. 5 2 135 119 1-17 0. 5 2 135 108 3-5 0. 5 2 135 108 1-18 0. 5 2 134 112 3-20 0. 5 2 134 118 1-28 0. 5 2 134 111 1-27 0. 5 2 133 115 3-19 0. 5 2 133 111 6-9 0. 5 2 133 113 1-24 0. 5 2 132 109 6-7 0. 5 2 132 114 1-15 0. 5 2 132 116 7-7 0. 5 2 132 110 5-4 0. 5 2 132 109 1-26 0. 5 2 131 111 6-15 0. 5 2 131 114 6-18 0. 5 2 131 117 3-7 0. 5 2 131 113 1-13 0. 1 1 131 119 7-5 0. 5 2 131 106 7-4 0. 5 2 131 108 5-9 0. 5 2 131 6-7 0. 5 2 131 116 3-16 0. 1 1 130 6-4 0. 1 1 117 8-5 0. 5 2 130 110 1-29 0. 1 l 130 117 5-8 0. 5 2 130 114 3-17 0. 5 2 130 110 7-6 0. 5 2 130 112 5-6 0. 5 2 130 115 7-15 0. 5 2 130 110 6-2 0. 5 2 130 106 6-19 0. 5 2 130 111 5-5 0. 5 l 129 114 3-11 0. 5 2 129 112 3-13 0. 5 1 129 114 7-12 0. 5 2 129 110 3-4 0. 1 1 129 117 l-16 0. 1 1 129 116 5-13 0. 5 2 129 110 6-11 0. 5 2 128 109 3-3 0. 5 2 128 117 6-13 0. 1 1 128 114 2-3 0. 5 2 128 108 5-3 0. 1 1 128 111 3-15 0. 5 2 128 112 5-7 0. 1 1 127 116 7-1 0. 1 1 127 115 7-2 0. 1 1 134 117 7-3 0. 1 1 127 110 3-12 0. 5 2 127 107 3-8 0. 5 2 127 106 4-4 0. 5 2 127 113 5-1 0. 5 1 127 113 1-23 0. 5 2 127 113 3-6 0. 5 2 127 107 6-20 0. 5 2 127 111 5-2 0. 5 2 126 107 5-11 0.5 2 126 109 6-1 0. 5 2 126 110 6-16 0. 5 2 126 111 3-2 0. 5 2 126 107 2-4 0. 5 2 126 110 7-14 0. 5 2 125 110 5-10 0. 5 2 125 106 1-14 0. 5 2 125 109 1-30 0. 5 2 125 106 4-3 0. 5 2 125 108 4-3 0. 5 2 125 108 6-22 0. 5 2 125 104 6-6 0. 1 1 124 114 2-2 0. 5 2 124 108 6-8 0. 5 1 127 110 l-25 O. 5 2 136 7-8 0. 5 2 121 7-10 0. 5 2 135 120 7-9 0. 5 2 131 117 3-18 0. 5 l 127 109 7-11 0. 5 1 126 113 Mixing Method: lin mixing extruder 2-stirring into molten polymer TABLE 13 [Evaluation of nucleation agents in polypropylene using difierential thermal analysis] Nucleatlng Agent DTA, 0. Test No. Clarity Code, Initial Peak Tables 1-0 3,367,926 1 1 Example 2 In manner like that of Example 1, various compositions of isotactic polypropylene and other nucleating agents identified in Tables 1-9 were prepared and tested by the DTA method. The data are shown in Table 11. 5 The polypropylene was a different lot of the same kind used in Example 1.

TABLE 11 [Evaluation of nucleation agents in polypropylene using differential thermal analysis] 10 n -01234-U67890123456789 10 -34567890123 0 5 12345 7 91 11 1 122222 2222 3333333334444 6 7 9 w a w a a a m a m a m .gyn .n m 5 66 6 k 5 i y i k tmA l6 0 8 3609112735077380354 11 t a 8144753426282333025 n .D lh n 0 m mnnmnnnnnnnmmnmunwn pmmzwwk m c m mmnnnmmnnnmnmnmnnnnn m wwwmm mm o m tl b e a f on v S Y O A l mme mlu M A l vmn em mo m T m aa owma aawmwaaaan n mm m L 1 i nfim in D H llmllllmwwllllllllll S at D H O U a at n 3 U n n u 0 r n 1.1111111111111111111 T I .1 C n H I raTs s I P aa .1 0 .1 .lie u w eeb leet0i mmw e m d w m m. gd O n n E n 6 ue e t6 mm w n m a mm mmmn wmmm WM 22222211222229.2221 11d p W m 222222222Z222l221l1 m w m T m f. O H M O F. 0 MM Eu 3 h 0 r 0 e ri lm P 5ml w mC dm1 0 am w mmmesfm now m 4 omwnm m km m t 0555555555555555552 1M mkwnm .w 1 W. HR 65555555555555155555 .Mw w Pu u. n miw m m m modoodoaaooaoduaodo m EWo/ WXw wlmm m mm mo0 0 0 0 n .0 o0 0 o0 0 0 0 0 0 0 0 W m w mm wmmme e .1 t M mu m m .mm amm mam l mu m m wmmfTwm marfw. C D 5 0 v. o a X .1 0 Th .lbe g .1 0 E P 1.1..0 T em g S S g. a n t r yl W i n 0 E n t i m P Hy D li pk e um n P d :C m y o m m mmnTmmm m m m a m em mwm m wm m m nv .1 C .l 1 r a arW ri Sa 2.

mammthwa M nwywm d S C B H n 0.1. g

u e D3 m 0 N I O fir. dn

" 30 t a oea u 1 m natt w L wtmhm mTcbSnn TABLE 13-C0nt1nue d TABLE 13-Con'6inued Nlfeating DTA o Nucleatin gen Agent g DTA, 0. Test No Clarity Test Clarity Code, Initial Peak Code, 11111161 Peak Tables Tables 1-9 1-109 125 120 4 1-27 125 119 4 2-26 125 118 4 6-26 134 130 3 2-27 125 115 4 1-92 134 129 3-4 1-110 124 120 4 6-27 134 129 3-4 1-10 124 119 4 6-23 134 123 2 2-23 123 117 4 1-93 133 129 3 1-32 123 117 4 1-94 133 129 4-3 2-29 133 126 1-2 1-95 133 129 3 2-19 130 112 4 1-96 133 128 2-3 2-30 129 114 4 6-29 133 123 4 2-31 129 110 4 6-30 133 123 3 2-32 123 116 4 6-24 133 123 4 2-33 127 112 4 1-97 133 127 2-3 2-34 126 112 4 1-93 132 127 4 2-36 126 111 4 1-99 132 127 3 2-36 125 110 4 1-100 132 127 4 2-37 124 113 4 1-101 132 125 3 2-33 124 110 4 1-35 131 126 3 9-6 126 120 4 1-102 131 125 3-4 193 2 1 37 micron particle size.

1-13 130 125 4 Example 5 6-1 130 124 2 j, 7-20 130 124 4 For purpose of demonstrating the benefits of the 1m- 11 1;: :3, provements of this invention on the mechanical proper- 6-31 129 124 4 ties of the products, various compositions of prevallingly :5; 138 g isotactic polypropylene with various added nucleating 1-26 128 124 4 agents were prepared, molded and tested with results 1 :3: ,1 shown in Table 14. The kind of polymer and kind and 2-22 1 7 123 2 amount of added nucleating agent are shown injthe E3 4 3 table. The tests labeled compression were carried out 127 121 4 on specimens prepared by melting and molding slabs 0.1 6-33 127 121 4 o H5 127 4 web thick in a compression mold at 200 (C. for 5 mini utes, then chilling the slab in ice water. The tests labeled Q 126 121 4 injection were carried out on specimens prepared by 3: E2 35 melting and injection molding 0.100 inch thick'by 5 inch H06 126 121 4 diameter disks in an injection mold at 25 F. above the 126 120 4 short-shot temperature. Tensile specimens were cut from 1-107 121 4 125 120 4 the moldings and tested 1n standard test methods for 122 i tensile yield strength and tensile modulus. The Table 40 14 also shows the DTA for these compositions.

TABLE 14.- [Elfect of nucleators on tensile properties of molded propylene samples] Nucleating Agent Tensile Properties Polypro- Diflerential Test pylene 7 Code Concen- Yield Modulus, Thermal Analysis, Molding No. Desig- Tables 1 tration, Strength, p.s.i. 10 0. Technique nation 1-9 Percent; 11.3.1. Initial Peak A 4, 400 132 103 Compression. A 0.1 4,900 155 126 A 0.1 4, 700 141 A 0.1 5,000 156 A 0.1 4, 700 147 A 0.1 151 A 0.1 4, 300 154 .4 0.1 4,700 143 A 0.1 4, 300 152 A 0.1 4,300 144 A 0.1 4,500 135 A 0.1 4, 600 148 A 0.1 4, 700 14s A 0.1 4, 700 144 A 0.1 4,600 137 B 4,000 132 B 0.2 4,300 B 0.2 4,400 134 B 0.2 4,500 142 B 0.2 4,500 139 B 0.2 4, 300 123 B 0.2 4,200 126 B 0.2 4, 300 131 B 0.2 4,300 131 B 0.2 4, 300 127 B 0.2 4, 300 129 B 0.2 4, 300 129 B 0.2 4,500 133 B 0.2 4,600 144 B 0.1 4, 300 14s 0 3,200 99 o 0.1 3,500 113 c 0.5 3, 500 115 D 3,000 39 D 0.5 3,400 107 1 Azl sotactic polypropylene, Melt Index 7.5, about 6% soluble in cold xylene; B:A different lot of the isotactic polypropylene described in A;

10 wt. percent polyisobutylene CzIsotactic polypropylene containing about rubber; DzIsotacti c polypropylene containing about 10 wt.

percent stereoregular polybutadiene rubber.

2 A graft eopoly'rner of acrylic acid on polypropylene. 3 A polyoxymethylene aeetal copolymer resin.

4 A nylon resin. 5 The sodium salt 01 an ethylene-acrylic acid copolymer.

1 Example 6 Compositions of high molecular weight prevailingly isotatic polystyrene and 0.5 percent by weight of various added nucleation agents were prepared by grinding the powdered isotatic polystyrene and powdered nucleator together in a dental mill. The resulting compositions were melted between a microscope slide and cover glass at 260 C. and transferred to the hot stage of a microscope for examination by the depolarized light intensity technique previously described. The isothermal procedure was used, holding the sample at 173 C. and measuring the induction time before initiation of crystallization. The results are shown in Table 15.

TABLE 15 [Nucleators for the crystallization 0t isotactic polystyrene] Test N0. Nueleating Agent Induction Time, Min.

Code, Tables 1-9 None 100 1-80 60 1-81 59 2-18 46 1-35 41 1-44 39 1-43 38 1-10 30 1-21 27 1-41 26 1-19 24 1-26 20 1-67 20 7-19 18 3-21 16 1-37 15 2-19 14 3-22 14 1-63 13 1-82 13 1-9 3-23 10 6-24 9. 1 1-39 8. 6 183 8.1 12 7. 5 1-17 7. 2 1-45 6. 6 1-84 4. 2 1-6 4. 0 1-46 3. 6 1-7 3. 5 1-12 3. 4 1-77 2. 7 1-85 2. 2 1-5 2. 1 1-71 1. 2

Example 7 Test portions of a crystallizable high molecular weight copolymer of ethylene and 6 percent by weight vinyl acetate are compounded with 0.5 percent by weight of one of the following nucleating agents: sodium acetate, sodium alizarinsulfonate, hydroquinone, phthalocyanine. The resulting compositions are melted and molded in an injection mold. In each instance, the rate of crystallization is faster and the size of the spherulites is smaller than in the product of similar molding of the starting polymer absent the added nucleating agent.

In'place of the particular crystallizable high polymers used in the foregoing examples there can be used another thermoplastic, crystallizable high polymer as hereinbefore described with substantially the same results.

When the compositions of thermoplastic, crystallizable high polymers and added nucleating agents in accordance with this invention are molded, the resulting molded articles have higher tensile strength, higher tensile modulus, and greater toughness in combination, fewer sink marks, less warpage, and often have better clarity than articles similarly molded from the' starting polymer absent the added nucleating agent, and are capable of being produced on shorter molding time cycle.

That which is claimed is:

1. In a process for fabricating articles from a thermoplastic crystallizable high polymer which on cooling from a molten condition tends to supercool without crystlalization to temperatures substantially below its crystalline melting point, the improvement which comprises modifying the crystalline structure of the polymer in such fabricated articles by compounding a composition of such thermoplastic crystallizable high polymer and a nucleation effective proportionate amount of at least about 10 parts per million by weight based on the polymer of an added nucleation agent which is chemically stable at temperatures above the crystalline melting point of the polymer and possesses a sterically ordered polar structure at temperatures below the crystalline melting point of the polymer, and which nucleation agent is selected from the compounds containing sulfur listed in Table 6 of the specification the composition being heated to a temperature above the crystalline melting point of the crystallizable polymer but below the decomposition temperature of the ingredients of the composition, shaping the composition and cooling the same to a temperature below the crystalline melting point of the crystallizable polymer, and crystallizing the crystallizable polymer, the added nucleation agent being present in the crystallizing composition as solid particles smaller than about 800 microns.

2. The improvement according to claim 1 wherein the thermoplastic crystallizable high polymer is a stereoregular polymer of an a-olefin.

3. The improvement according to claim 1 wherein the thermoplastic crystallizable high polymer is prevailingly isotactic polypropylene.

4. The improvement according to claim 1 wherein the thermoplastic crystallizable high polymer is prevailingly isotactic polystyrene.

5. An improved moldable composition of a thermoplastic crystallizable high polymer which on cooling from a molten condition tends to supercool without crystallization to temperatures substantially below its crystalline melting point compounded with a nucleation effective proportionate amount of at least about 10 parts per million by weight based on the polymer of an added nucleation agent which is chemically stable at temperatures above the crystalline melting point of the polymer and possesses a sterically ordered polar structure at temperatures below the crystalline melting point of the polymer, which composition, on being heated to a temperature above the crystalline melting point of the crystallizable polymer but below the decomposition temperature of the ingredients of the composition and cooling to a temperature below the crystalline melting point of the crystallizable polymer, contains the added nucleation agent as solid particles smaller than about 800 microns in diameter and crystallizes at a higher crystallizing temperature and at a faster crystallizing rate than the temperature and rate of such composition absent the added nucleation agent, which nucleation agent is selected from the compounds containing sulfur listed in Table 6 of the specification.

6. The improved moldable composition according to claim 5 wherein the crystallizable high polymer is a stereoregular polymer of an Ot-Olefin.

7. The improved moldable composition according to claim 5 wherein the crystallizable high polymer is prevailingly isotactic polypropylene.

8. The improved moldable composition according to t claim 5 wherein the crystallizable high polymer is prevailingly isotactic polystyrene.

9. An improved shaped article composed of a thermoplastic composition comprising a thermoplastic high polymer which on cooling from a molten condition tends to supercool without crystallizatin to temperatures substantially below its crystalline melting point, which composition is characterized by having the polymer component highly crystallized in the form of relatively small crystallites and spherulites intimately associated with uniformly dispersed finely divided solid particles smaller than about 800 microns in diameter of an added nucleation agent which is chemically stable at temperatures above the crystalline melting point of the polymer and possesses a Sterically ordered polar structure at temperatures below the crystalline melting point of the polymer and is present in nucleation-elfective proportionate amount of at least 10 parts per million by weight based on the polymer, which nucleation agent is selected from the compounds containing sulfur listed in Table 6 of the specification.

10. The improved shaped article according to claim 9 wherein the crystallized high polymer is a stereoregular polymer of an a-olefin.

11. The improved shaped article according to claim 9 wherein the crystallized high polymer is prevailingly isotactic polypropylene.

12. The improved shaped article according to claim 9 wherein the crystallized high polymer is prevailingly iso- 9/1965 Wijga 26094.9 9/1965 Wales 26094.9

m JOSEPH L. SCHOFER, Primary Examiner.

L. EDELMAN, Assistant Examiner. 

1. IN A PROCESS FOR FABRICATING ARTICLES FROM A THERMOPLASTIC CRYSTALLIZABLE HIGH POLYMER WHICH ON COOLING FROM A MOLTEN CONDITION TENDS TO SUPERCOOL WITHOUT CRYSLALIZATION TO TEMPERATURES SUBSTANTIALLY BELOW ITS CRYSTALLINE MELTING POINT, THE IMPROVEMENT WHICH COMPRISES MODIFYING THE CRYSTALLINE STRUCTURE OF THE POLYMER IN SUCH FABRICATED ARTICLES BY COMPOUNDING A COMPOSITION OF SUCH THERMOPLASTIC CRYSTALLIZABLE HIGH POLYMER AND A NUCLEATION EFFECTIVE PROPORTIONATE AMOUNT OF AT LEAST ABOUT 10 PARTS PER MILLION BY WEIGHT BASED ON THE POLYMER OF AN ADDED NUCLEATION AGENT WHICH IS CHEMICALLY STABLE AT TEMPERTURES ABOVE THE CRYSTALLINE MELTING POINT OF THE POLYMER, AND POSSESSES A STERICALLY ORDERED POLAR STRUCTURE AT TEMPERATURES BELOW THE CRYSTALLINE MELTING POINT OF THE POLYMER, AND WHICH NUCLEATIN AGENT IS SELECTED FROM THE COMPOUNDS CONTAINING SULFUR LISTED IN TABLE 6 OF THE SPECIFICATION THE COMPOSITION BEING HEATED TO A TEMPERATURE ABOVE THE CRYSTALLINE MELTING POINT OF CRYSTALLIZABLE POLYMER BUT BELOW THE DECOMPOSITION TEMPERATURE OF THE INGREDIENTS OF THE COMPOSITION, SHAPING THE COMPOSITON AND COOLING THE SAME TO A TEMPERATURE BELOW THE CRYSTALLINE MELTING POINT OF THE CRYSTALLIZABLE POLYMER, AND CRYSTALLIZING THE CRYSTALLIZABLE POLYMER, THE ADDED NUCLEATION AGENT BEING PRESENT IN THE CRYSTALLIZING COMPOSITION AS SOLIDS PARTICLES SMALLER THAN ABOVE 800 MICRONS. 